Process for preparing long chain alkyl aromatic compounds

ABSTRACT

Long chain alkyl aromatic compounds are prepared by alkylating an alkylatable aromatic compound with a long chain alkylating agent in the presence of catalyst comprising a synthetic porous crystalline material characterized by an X-ray diffraction pattern including interplanar d-spacings at 12.36±0.4, 11.03±0.2, 8.83±0.14, 6.18±0.12, 6.00±0.10, 4.06±0.07, 3.91±0.07 and 3.42±0.06 Angstroms.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 254,524, filed Oct. 6, 1988, which is a continuation-in-part of U.S. patent application Ser. No. 98,176, filed Sept. 18, 1987, now abandoned, which is a continuation-in-part of U.S. patent application Ser. No. 890,268, filed July 29, 1986, now abandoned.

BACKGROUND OF THE INVENTION

This invention relates to a process for preparing long chain alkyl aromatic compounds by alkylating an aromatic compound with a relatively long chain alkylating agent employing a synthetic porous crystalline material, or zeolite, as alkylation catalyst.

Zeolitic materials, both natural and synthetic, have been demonstrated in the past to have catalytic properties for various types of hydrocarbon conversion. Certain zeolitic materials are ordered, porous crystalline aluminosilicates having a definite crystalline structure as determined by X-ray diffraction, within which there are a large number of smaller cavities which may be interconnected by a number of still smaller channels or pores. These cavities and pores are uniform in size within a specific zeolitic material. Since the dimensions of these pores are such as to accept for adsorption molecules of certain dimensions while rejecting those of larger dimensions, these materials have come to be known as "molecular sieves" and are utilized in a variety of ways to take advantage of these properties. Such molecular sieves, both natural and synthetic, include a wide variety of positive ion-containing crystalline silicates. These silicates can be described as a rigid three-dimensional framework of SiO₄ and Periodic Table Group IIIA element oxide, e.g., AlO₄, in which the tetrahedra are cross-linked by the sharing of oxygen atoms whereby the ratio of the total Group IIIA element, e.g., aluminum, and silicon atoms to oxygen atoms is 1:2. The electrovalence of the tetrahedra containing the Group IIIA element, e.g., aluminum, is balanced by the inclusion in the crystal of a cation, e.g., an alkali metal or an alkaline earth metal cation. This can be expressed wherein the ratio of the Group IIA element, e.g., aluminum, to the number of various cations, such as Ca/2, Sr/2, Na, K or Li, is equal to unity. One type of cation may be exchanged either entirely or partially with another type of cation utilizing ion exchange techniques in a conventional manner. By means of such cation exchange, it has been possible to vary the properties of a given silicate by suitable selection of the cation. The spaces between the tetrahedra are occupied by molecules of water prior to dehydration.

Prior art techniques have resulted in the formation of a great variety of synthetic zeolites. Many of these zeolites have come to be designated by letter or other convenient symbols, as illustrated by zeolite Z (U.S. Pat. No. 2,882,243); zeolite X (U.S. Pat. No. 2,882,244); zeolite Y (U.S. Pat. No. 3,130,007); zeolite ZK-5 (U.S. Pat. No. 3,247,195); zeolite ZK-4 (U.S. Pat. No. 3,314,752); zeolite ZSM-5 (U.S. Pat. No. 3,702,886); zeolite ZSM-11 (U.S. Pat. No. 3,709,979); zeolite ZSM-12 (U.S. Pat. No. 3,832,449); zeolite ZSM-20 (U.S. Pat. No. 3,972,983); zeolite ZSM-35 (U.S. Pat. No. 4,016,245); and zeolite ZSM-23 (U.S. Pat. No. 4,076,842), merely to name a few.

The SiO₂ /Al₂ O₃ ratio of a given zeolite is often variable. For example, zeolite X can be synthesized with SiO₂ /Al₂ O₃ ratios of from 2 to 3; zeolite Y, from 3 to about 6. In some zeolites, the upper limit of the SiO₂ /Al₂ O₃ ratio is unbounded. ZSM-5 is one such example wherein the SiO₂ /Al₂ O₃ ratio is at least 5 and up to the limits of present analytical measurement techniques. U.S. Pat. No. 3,941,871 (Re. 29,948) discloses a porous crystalline silicate made from a reaction mixture containing no deliberately added alumina in the recipe and exhibiting the X-ray diffraction pattern characteristic of ZSM-5. U.S. Pat. Nos. 4,061,724, 4,073,865 and 4,104,294 describe crystalline silicates of varying alumina and metal content.

The alkylation of aromatic hydrocarbons with an olefin in the presence of a zeolite having uniform pore openings of from about 6 to about 15 Angstrom units is described in U.S. Pat. No. 2,904,607. U.S. Pat. No. 3,251,897 describes the alkylation of aromatic hydrocarbons in the presence of X- or Y-type zeolites, specifically such type zeolites wherein the cation is a rare earth metal species and/or hydrogen. U.S. Pat. Nos. 3,751,504 and 3,751,506 describe the vapor phase alkylation of aromatic hydrocarbons with olefins, e.g., benzene with ethylene, in the presence of a catalyst comprising, for example, ZSM-5.

U.S. Pat. Nos. 3,631,120 and 3,641,177, describe a liquid phase process for the alkylation of aromatic hydrocarbons with olefins in the presence of certain zeolites.

U.S. Pat. Nos. 4,301,316 and 4,301,317 disclose the use of such zeolites as ZSM-4, ZSM-20, ZSM-38, mazzite, Linde Type L and zeolite Beta to catalyze the alkylation of benzene with relatively long chain olefins to produce long chain alkylbenzenes.

SUMMARY OF THE INVENTION

It is an object of this invention to provide a process for the alkylation of an aromatic compound with a relative long chain alkylating agent to produce a long chain alkyl aromatic product employing as alkylation catalyst comprising a synthetic porous crystalline material characterized by an X-ray diffraction pattern including interplanar d-spacings at 12.36±0.4, 11.03±0.2, 8.83±0.14, 6.18±0.12, 6.00±0.10, 4.06±0.07, 3.91±0.07 and 3.42±0.06 Angstroms.

It is a particular object of the present invention to provide a process for producing predominantly 2- and 3-long chain alkylaromatics in which the aromatic ring is bonded to the alkylating agent predominantly in the 2- or 3-position of the latter.

It is another particular object of the invention to provide long chain alkylbenzenes which are useful, inter alia, as intermediates in the manufacture of synthetic detergents.

It is still another particular object of the present invention to provide a process for the alkylation of an aromatic hydrocarbon stream, e.g., one containing one or more of benzene, toluene, xylene, naphthalene, and the like, with a relatively long chain alkylating agent to produce an aromatic lube base stock of low pour and cloud point, high viscosity and improved thermal and oxidative stability properties.

By way of realizing the foregoing and other objects of the invention, a process for preparing long chain alkyl aromatic compounds is provided which comprises contacting at least one alkylatable aromatic compound with at least one alkylating agent possessing an alkylating aliphatic group having at least six carbon atoms under alkylation reaction conditions and in the presence of an alkylation catalyst to provide an alkylated aromatic product possessing at least one alkyl group derived from said alkylating agent, said catalyst comprising a synthetic porous crystalline material characterized by an X-ray diffraction pattern including values substantially as set forth in Tables A-D, infra.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-4 represent block-flow diagrams of various embodiments of the alkylation process of the present invention.

DESCRIPTION OF SPECIFIC EMBODIMENTS

The entire contents of application Ser. Nos. 254,524; 98,176; and 890,268 are incorporated herein by reference.

The term "aromatic" in reference to the alkylatable compounds which are useful herein is to be understood in accordance with its art-recognized scope which includes alkyl substituted and unsubstituted mono- and polynuclear compounds. Compounds of an aromatic character which possess a hetero atom are also useful provided they do not act as catalyst poisons under the reaction conditions selected.

Substituted aromatic compounds which can be alkylated herein must possess at least one hydrogen atom directly bonded to the aromatic nucleus. The aromatic rings can be substituted with one or more alkyl, aryl, alkaryl, alkoxy, aryloxy, cycloalkyl, halide, and/or other groups which do not interfere with the alkylation reaction.

Suitable aromatic hydrocarbons include benzene, toluene, xylene, naphthalene, anthracene, naphthacene, perylene, coronene and phenanthrene.

Generally the alkyl groups which can be present as substituents on the aromatic compound contain from one to about 22 carbon atoms and preferably from about one to eight carbon atoms, and most preferably from about one to four carbon atoms.

Suitable alkyl substituted aromatic compounds include toluene, xylene, isopropylbenzene, normal propylbenzene, alpha-methylnaphthalene, ethylbenzene, cumene, mesitylene, durene, p-cymene, butylbenzene, pseudocumene, o-diethylbenzene, m-diethylbenzene, p-diethylbenzene, isoamylbenzene, isohexylbenzene, pentaethylbenzene, pentamethylbenzene; 1,2,3,4-tetraethylbenzene; 1,2,3,5-tetramethylbenzene; 1,2,4-triethylbenzene; 1,2,3-trimethylbenzene, m-butyltoluene; p-butyltoluene; 3,5-diethyltoluene; o-ethyltoluene; p-ethyltoluene; m-propyltoluene; 4-ethyl-m-xylene; dimethylnaphthalenes; ethylnaphthalene; 2,3-dimethylanthracene; 9-ethylanthracene; 2-methylanthracene; o-methylanthracene; 9,10-dimethylphenanthrene; and 3-methyl-phenanthrene. Higher molecular weight alkylaromatic hydrocarbons can also be used as starting materials and include aromatic hydrocarbons such as are produced by the alkylation of aromatic hydrocarbons with olefin oligomers. Such product are frequently referred to in the art as alkylate and include hexylbenzene, nonylbenzene, dodecylbenzene, pentadecylbenzene, hexyltoluene, nonyltoluene, dodecyltoluene, pentadecyltoluene, etc. Very often alkylate is obtained as a high boiling fraction in which the alkyl group attached to the aromatic nucleus varies in size from about C₆ to about C₁₂.

Reformate containing substantial quantities of benzene, toluene and/or xylene constitutes a particularly useful feed for the alkylation process of this invention.

The alkylating agents which are useful in the process of this invention generally include any aliphatic or aromatic organic compound having one or more available alkylating aliphatic groups capable of reaction with the alkylatable aromatic compound. The alkylatable group itself should have at least about 6 carbon atoms, preferably at least about 8, and still more preferably at least about 12 carbon atoms. Examples of suitable alkylating agents are olefins such as hexenes, heptenes, octenes, nonenes, decenes, undecenes, dodecenes, and the like; alcohols (inclusive of monoalcohols, dialcohols, trialcohols, etc.) such as hexanols, heptanols, octanols, nonanols, decanols, undecanols and dodecanols; and alkyl halides such as hexyl chlorides, octyl chlorides, dodecyl chlorides; and, higher homologs of the foregoing. Branched alkylating agents, especially oligomerized olefins such as the trimers, tetramers, pentamers, etc., of light olefins such as ethylene, propylene, the butylenes, etc., are also useful herein.

In its calcined form, the synthetic porous crystalline material component employed in the catalyst composition used in the process of this invention is characterized by an X-ray diffraction pattern including the following lines:

                  TABLE A                                                          ______________________________________                                         Interplanar d-Spacing (A)                                                                     Relative Intensity, I/I.sub.o × 100                       ______________________________________                                         12.36 ± 0.4 M-VS                                                            11.03 ± 0.2 M-S                                                             8.83 ± 0.14 M-VS                                                            6.18 ± 0.12 M-VS                                                            6.00 ± 0.10 W-M                                                             4.06 ± 0.07 W-S                                                             3.91 ± 0.07 M-VS                                                            3.42 ± 0.06 VS                                                              ______________________________________                                    

Alternatively, it may be characterized by an X-ray diffraction pattern in its calcined form including the following lines:

                  TABLE B                                                          ______________________________________                                         Interplanar d-Spacing (A)                                                                     Relative Intensity, I/I.sub.o × 100                       ______________________________________                                         30.0 ± 2.2  W-M                                                             22.1 ± 1.3  W                                                               12.36 ± 0.4 M-VS                                                            11.03 ± 0.2 M-S                                                             8.83 ± 0.14 M-VS                                                            6.18 ± 0.12 M-VS                                                            6.00 ± 0.10 W-M                                                             4.06 ± 0.07 W-S                                                             3.91 ± 0.07 M-VS                                                            3.42 ± 0.06 VS                                                              ______________________________________                                    

More specifically, the calcined form may be characterized by an X-ray diffraction pattern including the following lines:

                  TABLE C                                                          ______________________________________                                         Interplanar d-Spacing (A)                                                                     Relative Intensity, I/I.sub.o × 100                       ______________________________________                                         12.36 ± 0.4 M-VS                                                            11.03 ± 0.2 M-S                                                             8.83 ± 0.14 M-VS                                                            6.86 ± 0.14 W-M                                                             6.18 ± 0.12 M-VS                                                            6.00 ± 0.10 W-M                                                             5.54 ± 0.10 W-M                                                             4.92 ± 0.09 W                                                               4.64 ± 0.08 W                                                               4.41 ± 0.08 W-M                                                             4.25 ± 0.08 W                                                               4.10 ± 0.07 W-S                                                             4.06 ± 0.07 W-S                                                             3.91 ± 0.07 M-VS                                                            3.75 ± 0.06 W-M                                                             3.56 ± 0.06 W-M                                                             3.42 ± 0.06 VS                                                              3.30 ± 0.05 W-M                                                             3.20 ± 0.05 W-M                                                             3.14 ± 0.05 W-M                                                             3.07 ± 0.05 W                                                               2.99 ± 0.05 W                                                               2.82 ± 0.05 W                                                               2.78 ± 0.05 W                                                               2.68 ± 0.05 W                                                               2.59 ± 0.05 W                                                               ______________________________________                                    

Most specifically, it may be characterized in its calcined form by an X-ray diffraction pattern including the following lines:

                  TABLE D                                                          ______________________________________                                         Interplanar d-Spacing (A)                                                                     Relative Intensity, I/I.sub.0 × 100                       ______________________________________                                         30.0 ± 2.2  W-M                                                             22.1 ± 1.3  W                                                               12.36 ± 0.4 M-VS                                                            11.03 ± 0.2 M-S                                                             8.83 ± 0.14 M-VS                                                            6.86 ± 0.14 W-M                                                             6.18 ± 0.12 M-VS                                                            6.00 ± 0.10 W-M                                                             5.54 ± 0.10 W-M                                                             4.92 ± 0.09 W                                                               4.64 ± 0.08 W                                                               4.41 ± 0.08 W-M                                                             4.25 ± 0.08 W                                                               4.10 ± 0.07 W-S                                                             4.06 ± 0.07 W-S                                                             3.91 ± 0.07 M-VS                                                            3.75 ± 0.06 W-M                                                             3.56 ± 0.06 W-M                                                             3.42 ± 0.06 VS                                                              3.30 ± 0.05 W-M                                                             3.20 ± 0.05 W-M                                                             3.14 ± 0.05 W-M                                                             3.07 ± 0.05 W                                                               2.99 ± 0.05 W                                                               2.82 ± 0.05 W                                                               2.78 ± 0.05 W                                                               2.68 ± 0.05 W                                                               2.59 ± 0.05 W                                                               ______________________________________                                    

These values were determined by standard techniques. The radiation was the K-alpha doublet of copper and a diffractometer equipped with a scintillation counter and an associated computer was used. The peak heights, I, and the positions as a function of 2 theta, where theta is the Bragg angle, were determined using algorithms on the computer associated with the diffractometer. From these, the relative intensites, 100 I/I_(o), where I_(o) is the intensity of the strongest line or peak, and d (obs.) the interplanar spacing in Angstrom Units (A), corresponding to the recorded lines, were determined. In Tables A-D, the relative intensities are given in terms of the symbols W=weak, M=medium, S=strong, VS=very strong. In terms of intensities, these may be generally designated as follows:

W=0-20

M=20-40

S=40-60

VS=60-100.

It should be understood that these X-ray diffraction patterns are characteristic of all species of the zeolite. The sodium form as well as other cationic forms reveal substantially the same pattern with some minor shifts in interplanar spacing and variation in relative intensity. Other minor variations can occur depending on the ratio of structural components, e.g. silicon to aluminum mole ratio of the particular sample, as well as its degree of thermal treatment.

Examples of such porous crystalline materials include the PSH-3 composition of U.S. Pat. No. 4,439,409, incorporated herein by reference, and MCM-22.

Zeolite MCM-22 has a composition involving the molar relationship:

    X.sub.2 O.sub.3 :(n)YO.sub.2,

wherein X is a trivalent element, such as aluminum, boron, iron and/or gallium, preferably aluminum, Y is a tetravalent element such as silicon and/or germanium, preferably silicon, and n is at least about 10, usually from about 10 to about 150, more usually from about 10 to about 60, and even more usually from about 20 to about 40. In the as-synthesized form, zeolite MCM-22 has a formula, on an anhydrous basis and in terms of moles of oxides per n moles of YO₂, as follows:

    (0.005-0.1)Na.sub.2 O:(1-4)R:X.sub.2 O.sub.3 :nYO.sub.2

wherein R is an organic component. The Na and R components are associated with the zeolite as a result of their presence during crystallization, and are easily removed by post-crystallization methods hereinafter more particularly described.

Zeolite MCM-22 is thermally stable and exhibits a high surface area greater than about 400 m² /gm as measured by the BET (Bruenauer, Emmet and Teller) test and unusually large sorption capacity when compared to previously described crystal structures having similar X-ray diffraction patterns. As is evident from the above formula, MCM-22 is synthesized nearly free of Na cations and thus possesses acid catalysis activity as synthesized. It can, therefore, be used as a component of the alkylation catalyst composition herein without having to first undergo an exchange step. To the extent desired, however, the original sodium cations of the as-synthesized material can be replaced in accordance with techniques well known in the art, at least in part, by ion exchange with other cations. Preferred replacement cations include metal ions, hydrogen ions, hydrogen precursor, e.g., ammonium, ions and mixtures thereof. Particularly preferred cations are those which tailor the activity of the catalyst for preparing long chain alkylaromatics. These include hydrogen, rare earth metals and metals of Groups IIA, IIIA, IVA, IB, IIB, IIIB, IVB and VIII of the Periodic Table of the Elements.

In its calcined form, zeolite MCM-22 appears to be made up of a single crystal phase with little or no detectable impurity crystal phases and has an X-ray diffraction pattern including the lines listed in above Tables A-D.

Prior to its use in the catalyst composition herein, the synthetic crystals should be subjected to thermal treatment to remove part or all of any organic constituent present therein.

The zeolite alkylation catalyst herein can also be used in intimate combination with a hydrogenating component such as tungsten, vanadium, molybdenum, rhenium, nickel, cobalt, chromium, manganese, or a noble metal such as platinum or palladium where a hydrogenation-dehydrogenation function is to be performed. Such component can be introduced in the catalyst composition by way of co-crystallization, exchanged into the composition to the extent a Group IIIA element, e.g., aluminum, is in the structure, impregnated therein or intimately physically admixed therewith. Such component can be impregnated in, or on, the zeolite such as, for example, by, in the case of platinum, treating the zeolite with a solution containing a platinum metal-containing ion. Thus, suitable platinum compounds for this purpose include chloroplatinic acid, platinous chloride and various compounds containing the platinum amine complex.

The zeolite, especially in its metal, hydrogen and ammonium forms, can be beneficially converted to another form by thermal treatment. This thermal treatment is generally performed by heating one of these forms at a temperature of at least about 370° C. for at least 1 minute and generally not longer than 20 hours. While subatmospheric pressure can be employed for the thermal treatment, atmospheric pressure is preferred simply for reasons of convenience. The thermal treatment can be performed at a temperature of up to about 925° C.

Prior to its use in the alkylation process of this invention, the zeolite crystals should be dehydrated, at least partially. This can be done by heating the crystals to a temperature in the range of from about 200° C. to about 595° C. in an atmosphere such as air, nitrogen, etc., and at atmospheric, subatmospheric or superatmospheric pressures for between about 30 minutes to about 48 hours. Dehydration can also be performed at room temperature merely by placing the crystalline material in a vacuum, but a longer time is required to obtain a sufficient amount of dehydration.

Zeolite MCM-22 can be prepared from a reaction mixture containing sources of alkali or alkaline earth metal (M), e.g., sodium or potassium, cation, an oxide of trivalent element X, e.g., aluminum, an oxide of tetravalent element Y, e.g., silicon, an organic (R) directing agent, hereinafter more particularly described, and water, said reaction mixture having a composition, in terms of mole ratios of oxides, within the following ranges:

    ______________________________________                                         Reactants      Useful   Preferred                                              ______________________________________                                         YO.sub.2 /X.sub.2 O.sub.3                                                                     10-60    10-40                                                  H.sub.2 O/YO.sub.2                                                                            5-100    10-50                                                  OH.sup.- /YO.sub.2                                                                            0.01-1.0 0.1-0.5                                                M/YO.sub.2     0.01-2.0 0.1-1.0                                                R/YO.sub.2     0.05-1.0 0.1-0.5                                                ______________________________________                                    

In a preferred method of synthesizing zeolite MCM-22, the YO₂ reactant contains a substantial amount of solid YO₂, e.g., at least about 30 wt. % solid YO₂. Where YO₂ is silica, the use of a silica source containing at least about 30 wt. % solid silica, e.g., Ultrasil (a precipitated, spray dried silica containing about 90 wt. % silica) or HiSil (a precipitated hydrated SiO₂ containing about 87 wt. % silica, about 6 wt. % free H₂ O and about 4.5 wt. % bound H₂ O of hydration and having a particle size of about 0.02 micron) favors crystal formation from the above mixture and is a distinct improvement over the synthesis method disclosed in U.S. Pat. No. 4,439,409. If another source of oxide of silicon, e.g., Q-Brand (a sodium silicate comprised of about 28.8 wt. % of SiO₂, 8.9 wt. % Na₂ O and 62.3 wt. % H₂ O) is used, crystallization may yield little if any MCM-22 crystalline material and impurity phases of other crystal structures, e.g., ZSM-12, may be produced. Preferably, therefore, the YO₂, e.g., silica, source contains at least about 30 wt. % solid YO₂, e.g., silica, and more preferably at least about 40 wt. % solid YO₂, e.g., silica.

Crystallization of the MCM-22 crystalline material can be carried out at either static or stirred conditions in a suitable reactor vessel such as, e.g., polypropylene jars or teflon-lined or stainless steel autoclaves. The total useful range of temperatures for crystallization is from about 80° C. to about 225° C. for a time sufficient for crystallization to occur at the temperature used, e.g., from about 25 hours to about 60 days. Thereafter, the crystals are separated from the liquid and recovered.

The organic directing agent for use in synthesizing zeolite MCM-22 from the above reaction mixture is hexamethyleneimine.

It should be realized that the reaction mixture components can be supplied by more than one source. The reaction mixture can be prepared either batchwise or continuously. Crystal size and crystallization time of the MCM-22 crystalline material will vary with the nature of the reaction mixture employed and the crystallization conditions.

In all cases, synthesis of the MCM-22 crystals is facilitated by the presence of at least about 0.01 percent, preferably about 0.10 percent and still more preferably about 1 percent, seed crystals (based on total weight) of the crystalline product.

The zeolite crystals can be shaped into a wide variety of particle sizes. Generally speaking, the particles can be in the form of a powder, a granule, or a molded product such as an extrudate having a particle size sufficient to pass through a 2 mesh (Tyler) screen and be retained on a 400 mesh (Tyler) screen. In cases where the catalyst is molded, such as by extrusion, the crystals can be extruded before drying or partially dried and then extruded.

It may be desired to incorporate the crystalline material with another material which is resistant to the temperatures and other conditions employed in the alkylation process of this invention. Such materials include active and inactive materials and synthetic or naturally occurring zeolites as well as inorganic materials such as clays, silica and/or metal oxides such as alumina. The latter may be either naturally occurring or in the form of gelatinous precipitates or gels including mixtures of silica and metal oxides. Use of a material in conjuction with the zeolite, i.e., combined therewith or present during its synthesis, which itself is catalytically active may change the conversion and/or selectivity of the catalyst. Inactive materials suitably serve as diluents to control the amount of conversion so that alkylation products can be obtained economically and orderly without employing other means for controlling the rate of reaction. These materials may be incorporated into naturally occurring clays, e.g., bentonite and kaolin, to improve the crush strength of the catalyst under commercial alkylation operating conditions. Said materials, i.e., clays, oxides, etc., function as binders for the catalyst. It is desirable to provide a catalyst having good crush strength because in commercial use, it is desirable to prevent the catalyst from breaking down into powder-like materials. These clay binders have been employed normally only for the purpose of improving the crush strength of the catalyst.

Naturally occurring clays which can be composited with the zeolite crystals include the montmorillonite and kaolin family, which families include the subbentonites, and the kaolins commonly known as Dixie, McNamee, Georgia and Florida clays or others in which the main mineral constituent is halloysite, kaolinite, dickite, nacrite, or anauxite. Such clays can be used in the raw state as originally mined or initially subjected to calcination, acid treatment or chemical modification. Binders useful for compositing with the zeolite also include inorganic oxides, notably alumina.

In addition to the foregoing materials, the zeolite crystals can be composited with a porous matrix material such as silica-alumina, silica-magnesia, silica-zirconia, silica-thoria, silica-beryllia, silica-titania as well as ternary compositions such as silica-alumina-thoria, silica-alumina-zirconia silica-alumina-magnesia and silica-magnesia-zirconia. It may also be advantageous to provide at least a part of the foregoing matrix materials in colloidal form so as to facilitate extrusion of the bound catalyst component(s).

The relative proportions of finely divided crystalline material and inorganic oxide matrix vary widely, with the crystal content ranging from about 1 to about 90 percent by weight and more usually, particularly when the composite is prepared in the form of beads, in the range of about 2 to about 80 weight percent of the composite.

The stability of the alkylation catalyst of the invention may be increased by steaming. U.S. Pat. Nos. 4,663,492; 4,594,146; 4,522,929; and 4,429,176, the entire disclosures of which are incorporated herein by reference, describe conditions for the steam stabilization of zeolite catalysts which can be utilized to steam-stabilize the catalyst for use herein. The steam stabilization conditions include contacting the catalyst with, e.g., 5-100% steam at a temperature of at least about 300° C. (e.g., 300°-650° C.) for at least one hour (e.g., 1-200 hours) at a pressure of 101-2500 kPa. In a more particular embodiment, the catalyst can be made to undergo steaming with 75-100% steam at 315°-500° C. and atmospheric pressure for 2-25 hours. In accordance with the steam stabilization treatment described in the above-mentioned patents, the steaming of the catalyst can take place under conditions sufficient to initially increase the Alpha Value of the catalyst, the significance of which is discussed infra, and produce a steamed catalyst having a peak Alpha Value. If desired, steaming can be continued to subsequently reduce the Alpha Value from the peak Alpha Value to an Alpha Value which is substantially the same as the Alpha Value of the unsteamed catalyst.

The alkylation process of this invention is conducted such that the organic reactants, i.e., the alkylatable aromatic compound and the alkylating agent, are brought into contact with the catalyst composition in a suitable reaction zone such as, for example, in a flow reactor containing a fixed bed of the catalyst composition, under effective alkylation conditions. Such conditions include a temperature of from about 0° to about 500° C., a pressure of from about 0.2 to about 250 atmospheres, a feed weight hourly space velocity (WHSV) of from about 0.1 hr⁻¹ to about 500 hr⁻¹ and an alkylatable aromatic compound to alkylating agent mole ratio of from about 0.1:1 to about 50:1. The WHSV is based upon the weight of the catalyst composition employed, i.e., the total weight of active catalyst (and binder if present). Preferred reaction conditions include a temperature within the approximate range of from about 100° C. to about 350° C., a pressure of from about 1 to about 25 atmospheres, a WHSV of from about 0.5 hr⁻¹ to about 100 hr⁻¹ and an alkylatable aromatic compound to alkylating agent mole ratio of from about 0.5:1 to about 5:1. The reactants can be in either the vapor phase or the liquid phase and can be neat, i.e., free from intentional admixture or dilution with other material, or they can be brought into contact with the zeolite catalyst composition with the aid of carrier gases or diluents such as, for example, hydrogen or nitrogen.

The alkylation process described herein can be carried out as a batch-type, semi-continuous or continuous operation utilizing a fixed or moving bed catalyst system. A preferred embodiment entails use of a catalyst zone wherein the hydrocarbon charge is passed concurrently or countercurrently through a moving bed of particle-form catalyst. The latter, after use, is conducted to a regeneration zone where coke is burned from the catalyst in an oxygen-containing atmosphere (such as air) at elevated temperature, after which the regenerated catalyst is recycled to the conversion zone for further contact with the organic reactants.

In order to more fully illustrate the alkylation process of this invention and the manner of practicing same, the following examples are presented. In the examples illustrative of the synthesis of zeolite, whenever sorption data are set forth for comparison of sorptive capacities for water, cyclohexane and/or n-hexane, they were Equilibrium Adsorption values determined as follows:

A weighed sample of the calcined adsorbent was contacted with the desired pure adsorbate vapor in an adsorption chamber, evacuated to less than 1 mm Hg and contacted with 12 Torr of water vapor or 40 Torr of n-hexane or 40 Torr of cyclohexane vapor, pressures less than the vapor-liquid equilibrium pressure of the respective absorbate at 90° C. The pressure was kept constant (within about ±0.5 mm Hg) by addition of adsorbate vapor controlled by a manostat during the adsorption period, which did not exceed about 8 hours. As adsorbate was adsorbed by the crystalline material, the decrease in pressure caused the manostat to open a valve which admitted more adsorbate vapor to the chamber to restore the above control pressures. Sorption was complete when the pressure change was not sufficient to activate the manostat. The increase in weight was calculated as the adsorption capacity of the sample in g/100 g of calcined adsorbant. Zeolite MCM-22 always exhibits Equilibrium Adsorption values of greater than about 10 wt. % for water vapor, greater than about 4.5 wt. %, usually greater than about 7 wt. % for cyclohexane vapor and greater than about 10 wt. % for n-hexane vapor. These vapor sorption capacities are a notable distinguishing feature of zeolite MCM-22 and are preferred for the zeolite component of catalyst for use herein.

When Alpha Value is examined, it is noted that the Alpha Value is an approximate indication of the catalytic cracking activity of the catalyst compared to a standard catalyst and it gives the relative rate constant (rate of normal hexane conversion per volume of catalyst per unit time). It is based on the activity of the highly active silica-alumina cracking catalyst taken as an Alpha of 1 (Rate Constant=0.016 sec⁻¹). The Alpha Test is described in U.S. Pat. No. 3,354,078, in the Journal of Catalysis, Vol. 4, p. 527 (1965); Vol. 6, p. 278 (1966); and Vol. 61, p. 395 (1980), each incorporated herein by reference as to that description. The experimental conditions of the test used herein include a constant temperature of 538° C. and a variable flow rate as described in detail in the Journal of Catalysis, Vol. 61, p. 395.

EXAMPLE 1

One part of sodium aluminate (43.5% Al₂ O₃, 32.2% Na₂ O, 25.6% H₂ O) was dissolved in a solution containing 1 part of 50% NaOH solution and 103.13 parts H₂ O. To this was added 4.50 parts hexamethyleneimine. The resulting solution was added to 8.55 parts of Ultrasil, a precipitated, spray-dried silica (about 90% SiO₂).

The reaction mixture had the following composition, in mole ratios:

SiO₂ /Al₂ O₃ =30.0

OH⁻ /SiO₂ =0.18

H₂ O/SiO₂ =44.9

Na/SiO₂ =0.18

R/SiO₂ =0.35

where R is hexamethyleneimine.

The mixture was crystallized in a stainless steel reactor, with stirring, at 150° C. for 7 days. The crystalline product was filtered, washed with water and dried at 120° C. After a 20 hour calcination at 538° C., the X-ray diffraction pattern contained the major lines listed in Table E. The sorption capacities of the calcined material were measured to be:

    ______________________________________                                         H.sub.2 O      15.2 wt. %                                                      Cyclohexane    14.6 wt. %                                                      n-Hexane       16.7 wt. %                                                      ______________________________________                                    

The surface area of the calcined crystalline material was measured to be 494 m² /g.

The chemical composition of the uncalcined material was determined to be as follows:

    ______________________________________                                         Component           wt. %                                                      ______________________________________                                         SiO.sub.2           66.9                                                       Al.sub.2 O.sub.3    5.40                                                       Na                  0.03                                                       N                   2.27                                                       Ash                 76.3                                                       SiO.sub.2 /Al.sub.2 O.sub.3, mole ratio =                                                          21.1                                                       ______________________________________                                    

                  TABLE E                                                          ______________________________________                                         Degrees    Interplanar                                                         2-Theta    d-Spacing (A)      I/I.sub.o                                        ______________________________________                                         2.80       31.55              25                                               4.02       21.98              10                                               7.10       12.45              96                                               7.95       11.12              47                                               10.00      8.85               51                                               12.90      6.86               11                                               14.34      6.18               42                                               14.72      6.02               15                                               15.90      5.57               20                                               17.81      4.98               5                                                20.20      4.40               20                                               20.91      4.25               5                                                21.59      4.12               20                                               21.92      4.06               13                                               22.67      3.92               30                                               23.70      3.75               13                                               24.97      3.57               15                                               25.01      3.56               20                                               26.00      3.43               100                                              26.69      3.31               14                                               27.75      3.21               15                                               28.52      3.13               10                                               29.01      3.08               5                                                29.71      3.01               5                                                31.61      2.830              5                                                32.21      2.779              5                                                33.35      2.687              5                                                34.61      2.592              5                                                ______________________________________                                    

EXAMPLE 2

A portion of the calcined crystalline product of Example 1 was tested in the Alpha Test and was found to have an Alpha Value of 224.

EXAMPLES 3-5

Three separate synthesis reaction mixtures were prepared with compositions indicated in Table F. The mixtures were prepared with sodium aluminate, sodium hydroxide, Ultrasil, hexamethyleneimine (R) and water. The mixtures were maintained at 150° C., 143° C. and 150° C., respectively, for 7, 8 and 6 days respectively in stainless steel autoclaves at autogenous pressure. Solids were separated from any unreacted components by filtration and then water washed, followed by drying at 120° C. The product crystals were subjected to X-ray diffraction, sorption, surface area and chemical analyses. The results of the sorption, surface area and chemical analyses are presented in Table F. The sorption and surface area measurements were of the calcined product.

                  TABLE F                                                          ______________________________________                                         Example            3        4      5                                           ______________________________________                                         Synthesis Mixture, mole ratios                                                 SiO.sub.2 /Al.sub.2 O.sub.3                                                                       30.0     30.0   30.0                                        OH.sup.- /SiO.sub.2                                                                               0.18     0.18   0.18                                        H.sub.2 O/SiO.sub.2                                                                               19.4     19.4   44.9                                        Na/SiO.sub.2       0.18     0.18   0.18                                        R/SiO.sub.2        0.35     0.35   0.35                                        Product Composition, Wt. %                                                     SiO.sub.2          64.3     68.5   74.5                                        Al.sub.2 O.sub.3   4.85     5.58   4.87                                        Na                 0.08     0.05   0.01                                        N                  2.40     2.33   2.12                                        Ash                77.1     77.3   78.2                                        SiO.sub.2 /Al.sub.2 O.sub.3, mole ratio                                                           22.5     20.9   26.0                                        Adsorption, Wt. %                                                              H.sub.2 O          14.9     13.6   14.6                                        Cyclohexane        12.5     12.2   13.6                                        n-Hexane           14.6     16.2   19.0                                        Surface Area, m.sup.2 /g                                                                          481      492    487                                         ______________________________________                                    

EXAMPLE 6

Quantities of the calcined (538° C. for 3 hours) crystalline silicate products of Examples 3, 4 and 5 were tested in the Alpha Test and found to have Alpha Values of 227, 180 and 187, respectively.

EXAMPLE 7

To demonstrate a further preparation of the present zeolite, 4.49 parts of hexamethyleneimine was added to a solution containing 1 part of sodium aluminate, 1 part of 50% NaOH solution and 44.19 parts of H₂ O. To the combined solution were added 8.54 parts of Ultrasil silica. The mixture was crystallized with agitation at 145° C. for 59 hours and the resultant product was water washed and dried at 120° C.

Product chemical composition, surface area and adsorption analyses results were as set forth in Table G:

                  TABLE G                                                          ______________________________________                                         Product Composition (uncalcined)                                               C                     12.1 wt. %                                               N                     1.98 wt. %                                               Na                    640 ppm                                                  Al.sub.2 O.sub.3      5.0 wt. %                                                SiO.sub.2             74.9 wt. %                                               SiO.sub.2 /Al.sub.2 O.sub.3, mole ratio                                                              25.4                                                     Adsorption, wt. %                                                              Cyclohexane           9.1                                                      N-Hexane              14.9                                                     H.sub.2 O             16.8                                                     Surface Area, m.sup.2 /g                                                                             479                                                      ______________________________________                                    

EXAMPLE 8

Twenty-five grams of solid crystal product from Example 7 were calcined in a flowing nitrogen atmospheres at 538° C. for 5 hours, followed by purging with 5% oxygen gas (balance N₂) for another 16 hours at 538° C.

Individual 3 g samples of the calcined material were ion-exchanged with 100 ml of 0.1N TEABr, TPABr and LaCl₃ solution separately. Each exchange was carried out at ambient temperature for 24 hours and repeated three times. The exchanged samples were collected by filtration, water-washed to be halide-free and dried. The compositions of the exchanged samples are tabulated below demonstrating the exchange capacity of the present crystalline silicate for different ions.

    ______________________________________                                                        Exchange Ions                                                   Ionic Composition, wt. %                                                                        TEA       TPA     La                                          ______________________________________                                         Na               0.095     0.089   0.063                                       N                0.30      0.38    0.03                                        C                2.89      3.63    --                                          La               --        --      1.04                                        ______________________________________                                    

EXAMPLE 9

The La-exchanged sample from Example 8 was sized to 14 to 25 mesh and then calcined in air at 538° C. for 3 hours. The calcined material had an Alpha Value of 173.

EXAMPLE 10

The calcined sample La-exchanged material from Example 9 was severely steamed at 649° C. in 100% steam for 2 hours. The steamed sample had an Alpha Value of 22, demonstrating that the zeolite has very good stability under severe hydrothermal treatment.

EXAMPLE 11

This example illustrates the preparation of the present zeolite where X in the general formula, supra, is boron. Boric acid, 2.59 parts, was added to a solution containing 1 part of 45% KOH solution and 42.96 parts H₂ O. To this was added 8.56 parts of Ultrasil silica, and the mixture was thoroughly homogenized. A 3.88 parts quantity of hexamethyleneimine was added to the mixture.

The reaction mixture had the following composition in mole ratios:

SiO₂ /B₂ O₃ =6.1

OH⁻ /SiO₂ =0.06

H₂ O/SiO₂ =19.0

K/SiO₂ =0.06

R/SiO₂ =0.30

where R is hexamethyleneimine.

The mixture was crystallized in a stainless steel reactor, with agitation, at 150° C. for 8 days. The crystalline product was filtered, washed with water and dried at 120° C. A portion of the product was calcined for 6 hours at 540° C. and found to have the following sorption capacities:

    ______________________________________                                         H.sub.2 O (12 Torr)                                                                              11.7 wt. %                                                   Cyclohexane (40 Torr)                                                                             7.5 wt. %                                                   n-Hexane (40 Torr)                                                                               11.4 wt. %                                                   ______________________________________                                    

The surface area of the calcined crystalline material was measured (BET) to be 405 m² /g.

The chemical composition of the uncalcined material was determined to be as follows:

    ______________________________________                                         N                       1.94 wt. %                                             Na                      175 ppm                                                K                       0.60 wt. %                                             Boron                   1.04 wt. %                                             Al.sub.2 O.sub.3        920 ppm                                                SiO.sub.2               75.9 wt. %                                             Ash                     74.11 wt. %                                            SiO.sub.2 /Al.sub.2 O.sub.3, molar ratio =                                                             1406                                                   SiO.sub.2 /(Al + B).sub.2 O.sub.3, molar ratio =                                                       25.8                                                   ______________________________________                                    

EXAMPLE 12

A portion of the calcined crystalline product of Example 11 was treated with NH₄ Cl and again calcined. The final crystalline product was tested in the Alpha Test and found to have an Alpha Value of 1.

EXAMPLE 13

This example illustrates another preparation of the zeolite in which X of the general formula, supra, is boron. Boric acid, 2.23 parts, was added to a solution of 1 part of 50% NaOH solution and 73.89 parts H₂ O. To this solution was added 15.29 parts of HiSil silica followed by 6.69 parts of hexamethyleneimine. The reaction mixture had the following composition in mole ratios:

SiO₂ /B₂ O₃ =12.3

OH⁻ /SiO₂ =0.056

H₂ O/SiO₂ =18.6

K/SiO₂ =0.056

R/SiO₂ =0.30

where R is hexamethyleneimine.

The mixture was crystallized in a stainless steel reactor, with agitation, at 300° C. for 9 days. The crystalline product was filtered, washed with water and dried at 120° C. The sorption capacities of the calcined material (6 hours at 540° C.) were measured:

    ______________________________________                                         H.sub.2 O (12 Torr)                                                                              14.4 wt. %                                                   Cyclohexane (40 Torr)                                                                             4.6 wt. %                                                   n-Hexane (40 Torr)                                                                               14.0 wt. %                                                   ______________________________________                                    

The surface area of the calcined crystalline material was measured to be 438 m² /g.

The chemical composition of the uncalcined material was determined to be as follows:

    ______________________________________                                         Component             Wt. %                                                    ______________________________________                                         N                     2.48                                                     Na                    0.06                                                     Boron                 0.83                                                     Al.sub.2 O.sub.3      0.50                                                     SiO.sub.2             73.4                                                     SiO.sub.2 /Al.sub.2 O.sub.3, molar ratio =                                                           249                                                      SiO.sub.2 /(Al + B).sub.2 O.sub.3, molar ratio =                                                     28.2                                                     ______________________________________                                    

EXAMPLE 14

A portion of the calcined crystalline product of Example 13 was tested in the Alpha Test and found to have an Alpha Value of 5.

EXAMPLE 15

This example shows the alkylation of benzene with 1-dodecene employing each of two known alkylation catalysts, namely, the Lewis acid AlCl₃ and zeolite Beta, such being disclosed in U.S. Pat. No. 4,301,316. The isomer distributions are shown in Table H as follows:

                  TABLE H                                                          ______________________________________                                         1-Dodecene Alkylation Isomer Distribution, Wt. %                               Alkybenzene                                                                    Isomer          AlCl.sub.3                                                                             Zeolite Beta                                           ______________________________________                                         2               30      57                                                     3               19      18                                                     4               17      10                                                     5               17       7                                                     6               17       8                                                     ______________________________________                                    

The composition of the dodecylbenzene mixture is to some extent dependent upon the acid catalyst involved. Sulfuric acid has been reported to result in 41 wt. % 2-dodecylbenzene while HF yields only 20 wt. % similar results can be shown for other alkylations involving relatively large, i.e., C₆ +, alkylating agents.

EXAMPLE 16

This example shows the alkylation of benzene with alpha-C₁₄ olefin (Shell's Neodene-14) over zeolite MCM-22 and separately over zeolite Beta. The specific MCM-22 used was prepared by adding 4.49 parts quantity of hexamethyleneimine to a mixture containing 1.00 part sodium aluminate, 1.00 part 50% NaOH, 8.54 parts Ultrasil VN3 and 44.19 parts deionized H₂ O. The reaction mixture was heated to 143° C. (290° F.) and stirred in an autoclave at that temperature for crystallization. After full crystallinity was achieved, the majority of the hexamethyleneimine was removed from the autoclave by controlled distillation and the zeolite crystals separated from the remaining liquid by filtration, washed with deionized H₂ O and dried.

A portion of the zeolite crystals was combined with Al₂ O₃ to form a mixture of 65 parts, by weight, zeolite and 35 parts Al₂ O₃. Water was added to this mixture to allow the resulting catalyst to be formed into extrudates. The catalyst was activated by calcining in nitrogen at 540° C. (1000° F.), followed by aqueous ammonium nitrate exchange and calcining in air at 540° C. (1000° F.).

Alkylation was carried out in a 1 liter autoclave using 400 grams (2.02 moles) olefin, 79 grams (1.01 moles) benzene and 38 grams of catalyst. Reaction time was six hours at 204° C. (400° F.) under 2860 kPa (400 psig) nitrogen. The isomer distributions are shown in Table I as follows:

                  TABLE I                                                          ______________________________________                                         Alkylation Isomer Distribution, Wt. %                                          Alkybenzene    Zeolite     Zeolite                                             Isomer         of the invention                                                                           Beta                                                ______________________________________                                         2              59.2        54.7                                                3              36.5        20.3                                                4              2.5         9.4                                                 5              0.9         5.8                                                 6              0.4         5.3                                                 7              0.5         5.5                                                 ______________________________________                                    

As the data in Examples 15 and 16 show, the use of the zeolite in accordance with this invention as alkylation catalyst results in a significantly higher percentage of alkylated product of the 2- and 3-alkyl isomer variety than a known Lewis acid or zeolite Beta alkylation catalyst under identical or similar conditions.

The alkylated products possessing alkyl side chains of approximately 8 to 16 carbon atoms are especially useful as intermediates for the production of linear alkylbenzene sulfonate synthetic detergents.

EXAMPLE 17

Two different zeolite catalysts, Alpha values of which are set forth in Table J below, were used in two separate alkylation runs, A and B, carried out under essentially identical conditions to provide lube base stocks. Each catalyst composition is 65% zeolite bound with 35 wt. % alumina.

                  TABLE J                                                          ______________________________________                                         Zeolite Catalyst MCM-22       Beta                                             Alpha Value      220          273                                              ______________________________________                                    

The alkylation reaction for each run was carried out in a 1 liter autoclave using 400 g (2.02 moles) of alpha C₁₄ olefin (Shell Neodene-14), 79 g (1.01 moles) of benzene (a 5:1 mole ratio of benzene to olefin) with 38 g catalyst at 400° F. for 6 hours under the nitrogen pressure of 400 psig.

Table K below sets forth the lube yield and lube properties resulting from alkylations carried out with each of the foregoing zeolites.

                  TABLE K                                                          ______________________________________                                                          Run A    Run B                                                Catalyst         MCM-22   Beta                                                 ______________________________________                                         Lube yield, wt. %                                                                               77.0     37.0                                                 Lube Properties:                                                               Pour Point, °F.                                                                          -60      -60                                                  Cloud Point, °F.                                                                         -38      -50                                                  KV at 40° C., cSt                                                                        12.59    14.54                                                KV at 100° C., cSt                                                                       3.151    3.471                                                VI               113      117                                                  ______________________________________                                    

Gas Chromatographic and Field Ionization Mass Spec (FIMS) analysis indicated that the synthetic lube produced from the MCM-22 catalyst contained a mixture of mono- and di-alkyl benzene compounds, 67 and 33 wt. %, respectively. The other catalyst, i.e., zeolite Beta, promoted not only alkylation to form mono- and di-alkyl benzenes but also C₁₄ oligomerization to form C₂₈ olefins. In addition to exhibiting a unique alkylation selectively, the MCM-22 catalyst is significantly more active and produces alkylated benzene lube base stock with very low pour and cloud point compared to zeolite Beta.

EXAMPLE 18

This example illustrates the excellent alkylation activity of zeolite MCM-22 catalyst with alpha C₁₄ olefin and naphthalene. The reaction was carried out under process conditions similar to those in Example 17 using a 0.5:1 mole ratio of alpha olefin to naphthalene. The alkylated naphthalene lube yield was about 94 wt. %, and the synthetic lube contained predominantly a mixture of mono-, di- and tri-alkyl naphthalenes and had the following properties (Table L):

                  TABLE L                                                          ______________________________________                                         Catalyst               MCM-22                                                  ______________________________________                                         Lube yield, wt. %      94                                                      Lube Properties                                                                Pour Point, °F. <-65                                                    KV at 40° C., cSt                                                                              37.27                                                   KV at 100° C., cSt                                                                             5.894                                                   VI                     100                                                     ______________________________________                                    

EXAMPLE 19

This example also illustrates the excellent activity and selectivity of zeolite MCM-22 catalyst for alkylating alpha C₁₄ olefin with other aromatics such as toluene (Example 19A) and xylene (Example 19B) as compared to benzene (Example 19C) under similar process conditions (Table M):

                  TABLE M                                                          ______________________________________                                                      Example No.                                                                    19A      19B      19C                                             ______________________________________                                         Aromatics      Toluene    Xylene   Benzene                                     Olefins        C.sub.14   C.sub.14 C.sub.14                                    Mole Ratios    1          1        1                                           C.sub.14 /Aromatics                                                            Lube Yield, wt. %                                                                             92.0       88.6     73.0                                        Lube Properties                                                                Pour Point, °F.                                                                        <-65       <-65     -45                                         Cloud Point, °F.                                                                       -65        -52      -44                                         KV at 40° C., cSt                                                                      9.408      16.13    7.651                                       KV at 100° C., cSt                                                                     2.505      3.393    2.265                                       VI             87         60       106                                         ______________________________________                                    

As illustrated in Examples 17 to 19, catalyst comprising the presently required synthetic crystalline material promotes the alkylation of various aromatics including benzene, toluene, xylene and naphthalene with alpha C₁₄ olefin to produce a unique class of aromatic-containing synthetic lube base stocks.

EXAMPLE 20

FIG. 1 is a schematic illustration of one embodiment of the alkylation process of the present invention. In accordance with this embodiment, olefin(s) in conduit 11, aromatic(s) in conduit 12 and any unconverted olefin(s) and/or aromatic(s) in recycle conduit 13 are introduced through conduit 14 into alkylation reaction zone 15 with the effluent therefrom being introduced through conduit 16 into a product recovery zone 17 (accomplished by conventional vacuum stripping or distillation techniques). The alkylated aromatic product(s) in conduit 18 can be subjected to one or more down-stream operations, e.g., hydrotreating/hydrofinishing, etc., represented generally at 19, to provide a finished lube base stock at 20.

Depending on the final and desired lube viscosity, the feed reactants can include long chain alpha olefins, e.g., C₈ -C₃₀ olefins, with the double bond located at the terminal (alpha) position or at some internal position, and the aromatic reactant can include single ring or double rings with or without substitution.

EXAMPLE 21

FIG. 2 is a schematic illustration of an alkylation process in accordance with this invention which utilizes an olefinic feedstock obtained from the oligomerization of 1-decene employing propanol-promoted BF₃ catalyst.

1-Decene in conduit 11, BF₃ in conduit 12 and propanol in conduit 13 were introduced through conduit 14 into oligomerization reactor 15 maintained under oligomerization reaction conditions. The oligomerized product in conduit 16 was combined with sodium hydroxide from conduit 17 in a first wash operation in 18, and thereafter with water from conduit 19 in a second wash operation 20 prior to separation of light products therefrom in vacuum distillation unit 21. Alkylation in accordance with the invention was carried out with 250 g of the 1-decene oligomers (250 g; 76 wt. %), containing 33 wt. % C₃₀ olefin, 52 wt. % C₄₀ olefin and 15 wt. % C₅₀ olefin, in alkylation reactor 22 with benzene (78 g; 24 wt. %) introduced therein through conduit 23. Reactor 22 contained 22 g zeolite MCM-22 and the reaction was carried out at 400 psig nitrogen and 400° F. for 6 hours.

After decanting the catalyst and distilling any unreacted benzene, the lube yield was about 88 wt. % indicating that about 12 wt. % benzene was alkylated and incorporated into the backbone structure of the decene oligomers. This was further confirmed by IR analysis. The properties of the oligomers before and after alkylation of the benzene are shown as follows (Table N):

                  TABLE N                                                          ______________________________________                                         PROCESS     OLIGOMERIZATION ALKYLATION                                         ______________________________________                                         Catalyst    BF.sub.3 -Propanol                                                                             Zeolite MCM-22                                     Lube Properties                                                                Pour Point, °F.                                                                     <-65            <-65                                               Cloud Point, °F.                                                                    <-65            <-65                                               KV at 40° C., cSt                                                                   25.73           33.03                                              KV at 100° C., cSt                                                                  5.225           6.039                                              VI          138             131                                                Product Quality                                                                Thermal Stability                                                                          10.9            4.6                                                at 550° F. % Vis.                                                       Decrease                                                                       B-10 Oxidative                                                                             120             80.6                                               Stability % Vis-                                                               cosity Increase                                                                DSC-IP, minutes                                                                            5.0             10.5                                               at 180° C.                                                              ______________________________________                                    

The results indicate that the zeolite MCM-22 catalyzed alkylation step produces a benzene-containing synthetic lube base stock with excellent product properties such as very low pour, cloud point (-65° F.) and high Viscosity Index (131 VI) together with improved additive solvency characteristics as well as enhanced termal and oxidative stability.

As shown in FIG. 2, the lube base stock can be subjected to one or more down-stream finishing operations shown generally at 24.

EXAMPLE 22

FIG. 3 is a schematic illustration of the alkylation process of this invention carried out with a 1-decene oligomer product obtained with Cr/SiO₂ catalyst.

Thus, 1-decene in conduit 11 and Cr/SiO₂ in conduit 12 were introduced into oligomerization reactor 15 with the product therefrom being vacuum stripped in 21 and thereafter being introduced into alkylation reactor 22 together with benzene from conduit 23. As in the process shown in FIG. 2, the lube stock can be further treated, for example, by hydrofinishing, shown generally at 24.

The alkylation reaction was carried out under identical process conditions as in Example 21 but using 500 g decene oligomers and 95 g of benzene with 36 g of zeolite MCM-22 catalyst. The properties of the decene oligomers before and after alkylation of the benzene are shown as follows (Table 0):

                  TABLE O                                                          ______________________________________                                         PROCESS     OLIGOMERIZATION ALKYLATION                                         ______________________________________                                         Catalyst    Cr/SiO.sub.2    Zeolite MCM-22                                     Lube Properties                                                                Pour Point, °F.                                                                     -30             -25                                                Cloud Point, °F.                                                                    <-65            -30                                                KV at 40° C., cSt                                                                   122.9           68.11                                              KV at 100° C., cSt                                                                  18.33           11.60                                              VI          167             166                                                ______________________________________                                    

EXAMPLE 23

FIG. 4 illustrates the combination of ZSM-5 catalyzed conversion of light olefin (introduced through conduit 11 into olefin conversion reactor 15) to provide gasoline and distillate with the MCM-22 catalyzed alkylation of the latter in alkylation reactor 22 providing an aromatic-containing lube base stock from which light components are removed, e.g., by vacuum distillation in unit 21, followed by optional downstream finishing in unit 24. In a manner similar to Example 21, 400 g of 400°-700° F. distillate (78 wt. %) was alkylated with 115 g naphthalene (12 wt. %) (conduit 23) over MCM-22 catalyst. The resulting 700° F.+ lube yield was about 54 wt. %. Table P shows the properties of the alkylated naphthalene lube base stock:

                  TABLE P                                                          ______________________________________                                                     OLEFIN                                                                         CONVERSION                                                                     TO GASOLINE                                                        PROCESS     AND DISTILLATE  ALKYLATION                                         ______________________________________                                         Catalyst    Zeolite ZSM-5   Zeolite MCM-22                                     Properties                                                                     Pour Point,°F.                                                                      <-65            0                                                  KV at 40° C., cSt                                                                   --              152.6                                              KV at 100° C., cSt                                                                  2.5             10.15                                              Sim. Dist.,                                                                    D-2887, °F.                                                             IBP/5%      300/375         636/679                                            10/20%      435/467         701/732                                            30/40%      488/509         754/776                                            50%         529             799                                                60/70%      553/583         825/856                                            80/90%      622/679         894/948                                            95%         725             990                                                ______________________________________                                     

What is claimed is:
 1. A process for preparing long chain alkyl aromatic compounds which comprises contacting at least one alkylatable aromatic compound with at least one alkylating agent possessing an alkylating aliphatic group having at least six carbon atoms under alkylation reaction conditions and in the presence of an alkylation catalyst to provide an alkylated aromatic product possessing at least one alkyl group derived from said alkylating agent, said catalyst comprising a synthetic porous crystalline material characterized by an X-ray diffraction pattern including values substantially as set forth in Table A of the specification.
 2. The process of claim 1 wherein the synthetic porous crystalline material is characterized by an X-ray diffraction pattern including values substantially as set forth in Table B of the specification.
 3. The process of claim 1 wherein the synthetic porous crystalline material is characterized by an X-ray diffraction pattern including values substantially as set forth in Table C of the specification.
 4. The process of claim 1 wherein the synthetic porous crystalline material is characterized by an X-ray diffraction pattern including values substantially as set forth in Table D of the specification.
 5. The process of claim 1 wherein the synthetic porous crystalline material has a composition comprising the molar relationship

    X.sub.2 O.sub.3 :(n)YO.sub.2,

wherein n is at least about 10, X is a trivalent element and Y is a tetravalent element.
 6. The process of claim 2 wherein the synthetic porous crystalline material has a composition comprising the molar relationship:

    X.sub.2 O.sub.3 :(n)YO.sub.2,

wherein n is at least about 10, X is a trivalent element and Y is a tetravalent element.
 7. The process of claim 3 wherein the synthetic porous crystalline material has a composition comprising the molar relationship

    X.sub.2 O.sub.3 :(n)YO.sub.2,

wherein n is at least 10, X is a trivalent element and Y is a tetravalent element.
 8. The process of claim 4 wherein the synthetic porous crystalline material has a composition comprising the molar relationship

    X.sub.2 O.sub.3 :(n)YO.sub.2,

wherein n is at least about 10, X is a trivalent element and Y is a tetravalent element.
 9. The process of claim 1 wherein the synthetic porous crystalline material possesses equilibrium adsorption capacities of greater than about 4.5 wt. % for cyclohexane vapor and greater than about 10 wt. % for n-hexane vapor.
 10. The process of claim 5 wherein X is selected from the group consisting of aluminum, boron, gallium and combinations thereof and Y is selected from the group consisting of silicon, germanium and combinations thereof.
 11. The process of claim 5 wherein X comprises aluminum and Y comprises silicon.
 12. The process of claim 1 wherein said synthetic porous crystalline material has been treated to replace original cations, at least in part, with a cation or mixture of cations selected from the group consisting of hydrogen, hydrogen precursors, rare earth metals, and metals of Groups IIA, IIIA, IVA, IB, IIB, IIIB, IVB, VIB and VIII of the Periodic Table.
 13. The process of claim 1 wherein said synthetic porous crystalline material has been thermally treated at a temperature up to about 925° C. in the presence or absence of steam.
 14. The process of claim 12 wherein said synthetic porous crystalline material has been thermally treated at a temperature up to about 925° C. in the presence or absence of steam.
 15. The process of claim 1 wherein said synthetic porous crystalline material is combined with a material matrix.
 16. The process of claim 15 wherein said matrix material is a silica or alumina-containing material.
 17. The process of claim 15 wherein the catalyst is provided in the form of extrudate, beads or fluidizable microspheres.
 18. The process of claim 1 wherein the alkylating aliphatic group contains at least about 8 carbon atoms.
 19. The process of claim 1 wherein the alkylating aliphatic group contains at least about 12 carbon atoms.
 20. The process of claim 1 wherein the alkylating agent is an olefin.
 21. The process of claim 1 wherein the alkylating agent is an alcohol.
 22. The process of claim 1 wherein the alkylating agent is an alkyl halide.
 23. The process of claim 1 wherein the alkylatable aromatic compound is selected from the group consisting of benzene, xylene, toluene and 1,2,3,5-tetramethylbenzene.
 24. The process of claim 1 wherein the alkylatable aromatic compound is selected from the group consisting of naphthalene, anthracene, naphthacene, perylene, coronene and phenanthrene.
 25. The process of claim 1 wherein the alkylation reaction conditions include a temperature of from about 0° C. to about 500° C., a pressure of from about 0.2 to about 25 atmospheres, an WHSV of from about 0.1 hr⁻¹ to 500 hr⁻¹ and an alkylatable aromatic compound to alkylating agent mole ratio of from about 0.1:1 to 50:1.
 26. The process of claim 1 wherein the alkylation reaction conditions include a temperature of from about 100° C. to 350° C., a pressure of from about 1 to about 25 atmospheres, a WHSV of from about 0.5 hr⁻¹ to about 100 hr⁻¹ and an alkylatable aromatic compound to alkylating agent mole ratio of from about 0.5:1 to about 5:1.
 27. A process for alkylating an alkylatable polynuclear aromatic hydrocarbon which comprises contacting the alkylatable polynuclear aromatic hydrocarbon with an olefinic alkylating agent having at least about 6 carbon atoms under alkylation reaction conditions and in the presence of an alkylation catalyst comprising a synthetic porous crystalline material characterized by an X-ray diffraction pattern including values substantially as set forth in Table A of the specification.
 28. The process of claim 27 wherein the polynuclear aromatic hydrocarbon is selected from the group consisting of naphthalene, anthracene, perylene, coronene and phenanthrene.
 29. The process of claim 27 wherein the olefinic alkylating agent contains at least about 12 carbon atoms. 